WHY DO YOU WANT YOUR PEOPLE AS CERTIFIED PROFESSIONALS



Injection Molding Professional

Certification

Created and administered by

WJT Associates

Copyright 2012

INDEX

The Program An explanation of the program and how to begin. (2 Pages)

The Contract A contract for completion of the program and costs (2 pages)

PROJECT WORK SHEET FORMAT FAQs Frequently asked questions (3 pages)

POSSIBLE PROJECTS A listing of common projects. The student may choose their own (1 page)

PROJECTS

PROJECT WORKSHEET FORMAT The generalized format for

reporting all projects (1 Page)

PROJECT WORKSHEET The sheet to be filled out (1 page)

COMPLETION CHECK LIST A summarization of all work planned and/or

completed (1 page)

SCIENTIFIC MOLDING EXAM (1 PAGE)

TROUBLESHOOTING EXAM (1 PAGE)

TROUBLESHOOTING EXAM WORKSHEET (1 PAGE)

TRAINING RESOURCES A listing of training programs (1 PAGE)

DEFINITIANS (1 PAGE)

THE PROGRAM

PURPOSE:

The program is designed to improve the company’s profitability through the Student’s proving his skill in the application of the skills of Scientific Molding and Troubleshooting to his job as well as implementing cost savings project to the company thereby financing a raise.

DESCRIPTION:

The program is a joint effort between a designated person (‘Supervisor’) who will supervise and approve the student’s work, the student who will do the actual work, and a representative of WJT Associates (‘Mentor’) who will offer consultative advice throughout the program, approve the project’s completion and award the certification.

On completion of the program, the student will retain the files of his work for his own records. The student will receive an increase in pay in accordance with The Contract. The student will receive a certificate certifying him or her as a Injection Molding Professional as well as a wallet card. The company will receive an engraved plaque to display who has achieved this certification.

BEGINNING THE PROGRAM:

WJT Associates must receive the following before beginning the program:

1. A signed Contract between the Supervisor and the Student stating the following:

a) The current and proposed pay the student will get as a result of completing the program.

b) A brief description of all the proposed projects the student will complete within the time limits of the program.

c) The estimated start and completion dates.

2. Fully paid tuition for the program.

THE PROGRAM REQUIREMENTS

Each portion of the program must be signed by the Student and the Supervisor in a timely manner and then submitted by e-mail to WJT Associates’ assigned Mentor for grading or co-signature. The signature portion of each requirement will be then e-mailed back to the student for his records.

There is no particular order for the different parts of this program. Completion of the program will be determined by finishing the work as summarized on the Completion Check List.

There is no requirement that the student attend WJT Associates’ seminars. The knowledge required to pass the tests can be acquired from any reputable source. The lists of projects are only suggestions. Any project that will improve the company’s productivity that is acceptable to the ‘supervisor’ and WJT Associates can be used.

To obtain the certificate the student must complete and receive a passing grade on the following:

SCIENTIFIC MOLDING EXAM – See attached

TROUBLESHOOTING EXAM – See attached.

PROJECTS – See attached – totaling a minimum of 100 hours work.

The Program Page 1 of 2

TUITION

Five people minimum –

- WITHOUT in-house seminars - $6,000 USD for five students

- With seminars (one trip, within the USA, two complete classroom days set up at both party’s convenience.) - $7500 for five students

- Additional individuals added within the initial 6 month time frame - $1500 each. The additional students can attend the in-house seminars for no charge if attended at the same time as the original five students attend.

- Students will receive textbooks

Individuals –

- Without In-house seminars. – $1750 per student

- Public Seminars given by WJT Associates will award a 50% credit for normally charged tuition is in the program at the time of the seminars.

- Students will receive textbooks

Tuition must be fully paid at the beginning of the program made out to WJT Associates and mailed to the address at the top of the page.

The Program Page 2 of 2

Contract

Recitals:

1. References to the ‘Company’, the ‘Student’, and the ‘hereinafter’ are to be construed as those described above and agreed to by their signatures below.

2. This is a contract between WJT Associates, the Company, and the Student.

The Contract:

The Student and the Supervisor have constructed a plan of a minimum of one hundred (100) work hours to pursue a Injection Molding Professional Certificate program as outlined and administered by WJT Associates and completed within six (6) calendar months after the beginning of the program.

The Student or Supervisor will submit the plan, signed and agreed to by both, to WJT Associates along with the tuition for the certificate program by e-mail. With WJT’s Mentor’s co-signing the contract the certificate and returning it by e-mail the program will begin.

Student’s responsibilities: The student agrees to accomplish the projects listed and

e-mail reports on each completion to the Supervisor and the Mentor and further agrees to take and receive a passing grade on the Scientific Molding exam and the Troubleshooting exam within six month of receipt of approval of this program by WJT Associates.

Supervisor’s Responsibilities: The Supervisor will oversee the work done by the Student and signoff on the completed Projects in a timely manner. Where capitol expenditures are required as a result of the project, the student will only recommend the purchase and show the potential return on investment. If the Supervisor chooses not to approve the purchase of the recommended equipment, the student will be credited with the ‘calculated’ savings.

The Supervisor agrees on receiving confirmation from WJT Associates assigned Mentor that all work has been accomplished and approved within the six month allotted time to increase the Student’s salary as follows (financed by the savings accrued from the Students increased skill level and the successful outcome of the projects):

Student’s salary at the beginning of the program is $ ___________ / month

Having completed the program; as a Certified Injection Molding Professional the

Student’s salary will be $ ___________ /month immediately upon notification of having completed the program.

Contract Page 1 of 2

WJT’s responsibilities: On receipt of the application and tuition, WJT Associates will assign a Mentor for the Student, cosigning the program and providing contact information with the Mentor, The Mentor will approve the proposed program, critique and grade (pass/fail) each of the projects and the exams. The Mentor will be available for consultative advice to the student to assist technically for a maximum of ten hours per student unless otherwise agreed to.

WJT will provide publications on Scientific Molding, Tooling Maintenance, and Troubleshooting for each student at the beginning of the program on receipt of the tuition.

On the successful completion of the program as noted by a signed Completion Check list; WJT will provide an authorize diploma to each student for the program and a wallet ID card. The Company will receive a plaque citing the program and the names of the individuals whom have successfully completed it.

Authorized Signatures

Supervisor ____________________________________ Date _______________

Student ____________________________________ Date _______________

The program is considered to be approved with the signature below. The date is to be considered the program’s start date.

WJT Associates ____________________________________ Date _______________

Information:

Company Name:_____________________________________ (the ‘company’)

Company address _____________________________________

General Phone # _____________________________

Fax # ______________________________

Name and e-mail of Company designated representative (the ‘Supervisor’)

_______________________________________________________

Student Full Name: __________________________________________ (the’Student’)

Student’s e-mail address_____________________________

Contract Page 2 of 2

FAQ

WHY DO YOU WANT YOUR PEOPLE AS CERTIFIED PROFESSIONALS?

You not only hire people to work for you, you hire them to have specialized skills that can be brought to bear on your operation to maximize your profits. This program provides not only the general training in molding but also sets out specialized training for your operation alone.

WHY DO IT?

People are your best assets. Retaining your best trained people will maximize your profits. This program is designed so that both management and the students Must Be committed to completing it.

WHAT’S SO SPECIAL ABOUT THIS PROGRAM?

There are three common complaints about training:

COMPLAINT #1 - “It’s generic. Training is fine but it doesn’t exactly fit into my company’s philosophy.”

SOLUTION#1 – Yes Scientific Molding and Troubleshooting are generic. Molding is molding. While someone trained to optimize the molding process and troubleshoot defects is a contributor, there are other ‘special projects’ unique to your operation that generic training doesn’t cover. It is not only important that the tech receive training but also that they use it. Further, they must be able to use it and other techniques to improve your operation. This is done by having the student write out, descriptions and examples of how they applied the knowledge they’ve learned including the additional profit they brought to the company as a result of this work. This must be approved by both the company management and WJT Associates.

PROBLEM #2 – “All they want to really do is sell me gadgets (signal controllers, data collectors etc.).”

SOLUTION #2 This program is not about selling computer programs, black boxes or anything else. It’s about using what you have to its fullest. As part of the student’s special projects they will evaluate the current production situation (usually in dollars), propose solutions – sometimes with the purchase of equipment (but not without a sufficient ROI and justification) – and then implement the solution showing the permanent profit obtained.

PROBLEM #3 – “I pay for all this training and then they quit and go elsewhere.”

SOLUTION #3 People change jobs because they feel they aren’t paid what they’re worth. Management is quick to point out “This is what I pay you for!!” If the company is making a profit with whole percentages of scrap, setups that take hours, and non-standard cycle times; you got what you paid for.

Henry Ford, while probably not the first to use this technique, popularized the concept of “Golden Handcuffs”. He paid his workers 3X the going wage so if they quit and went elsewhere they’d take a dramatic cut in their income.

FAQ Page 1 of 3

Solution #3 (Con’t)

This program is not about tripling the wages of your techs. However, in the beginning management will sign a contract that says at the end of the program, the student will get a permanent raise that will put the pay level substantially above the current pay levels. An interesting side benefit to this thinking is that those who complete the program will be able to train others and this core group of people will become future executives of your company.

YOU’RE ASKING MANAGEMENT TO SIGN A CONTRACT GUARANTEEING A RAISE FOR THE STUDENT. WHY? WHERE WILL I GET THE MONEY?

When you send someone to a seminar – What’s the incentive to learn? Piling on extra work with no reward is poor motivator. Every inefficiency, delay in production, piece of scrap, rejected shipment has a price you must pay for. But what if you could avoid a significant percentage of it?

This program has the student generate the savings (reduced head count, less scrap, better productivity etc.) ahead of time and prove that they did it. The key here is to offer a large enough salary increase (20-30%) that, should the student choose to leave, they’ll also take a significant cut in pay.

The actual increase in pay is self-financing. The usual result of these programs, if carefully chosen, will result in the savings and profit improvements that are usually a minimum of 10X more than the cost of the increase in pay. Since the student is being paid only a fraction of what is saved, this is a Win-Win for everyone that will continue into the future.

DO I HAVE TO ATTEND WJT ASSOCIATES’ SEMINARS?

No, it is not mandatory to attend any WJT Associates seminars or anyone else’s. The knowledge and experience necessary to complete this program can be from books, training materials, personal experience or any competent instructor.

WHAT IS CONSULTIVE ADVICE? – ‘Free Consulting’?

In regards to the certification program, WJT Associates will provide what is typically referred to as ‘free consulting’ for up to 10 hours/student either by phone or e-mails. This will be limited to consulting on the student’s projects or answering questions on Scientific Molding / Troubleshooting that are not mentioned in the training materials.

WHAT IF PEOPLE “GAME” THE PROGRAM?

This is a joint program between the student, the company management and WJT Associates. Management and the student agree on and review the projects, their progress, and successes. WJT Associates through its representatives will offer consultative advice throughout each project as well as ‘grade’ the reports and proposals that the student’s complete. With management and the student choosing the projects and assessing the successes in terms of improved profits and WJT Associates assessing the technical side, it is difficult to ‘game’ this program and not improve productivity.

FAQ Page 2 of 3

HOW DOES MANAGEMENT (SUPERVISION) FIT INTO THIS PROGRAM

Management must actively participate in this program. Management will commit to your increase in pay as a result of the money you’ve saved/generated through your work. Management must approve the student’s proposed work on Projects.

It is in their best interest to choose projects that will show increased profits. If the purchase of new equipment is recommended and justified as a result of your work on projects, it is expected that they will follow through on your recommendations.

WHAT IF THE PROJECT I’D LIKE TO WORK ON ISN’T ON THE LIST?

The list of projects is only a list of suggested projects. Any project the student and management can come up with to improve your company’s profitability is acceptable.

WHAT IF THE PROJECT I UNDERTAKE FAILS?

Let’s assume you undertook a project that you estimated would save 10% but only saved 3%. Although this wasn’t as big a game changer as you’d like, you both learned what worked AND what didn’t. This makes the project a success.

WHAT ARE THE CRITERIA FOR PASSING THE EXAMS/PROJECTS

The exams and projects are graded on a PASS / FAIL basis determined by WJT Associates. The student should review the exam answers with both his company and WJT before submitting it for grading.

WHAT IF I FAIL THE EXAM? CAN I DO IT OVER AGAIN?

Yes, however you may resubmit your exam answers a second time if you receive an initial failing grade. If you receive a failing grade twice, you must start the program over again, repaying tuition etc.

WHY IS THERE A TIME LIMIT ON THE PROGRAM?

The incentive for the student is the increase in pay after completing the program. The money to pay him is gained from productivity improvements. Obviously training will not show permanent results in a few weeks. Stretching the program out longer than the allotted time will quickly lose the incentive for the student. The program from start to finish should take no longer than six months.

FAQ Page 3 of 3

POSSIBLE PROJECTS

This is a list of possible projects but is by no means a complete listing. Add in any other additional projects that can significantly contribute to your specific molding operation.

1. Reduce hot runner failures – blockage, electrical failures

2. Set up a mold preventative maintenance program

3. Set up a machine maintenance program

4. Check and repair/correct all machine for being level and the platens being parallel

5. Test the reliability (repeatability) program on a minimum of 10 machines. Make recommend repairs accordingly

6. Set up a program to run full cavitation on all molds.

7. Check and correct all off cycle processes. Show improvement for 90 days. Embed changes

8. Reduce current cycle times an average of 5% on X% of the molds

9. Find, report, and correct molds that are mismatched to the machine in terms of clamp pressure or shot size to the mold.

10. Test machines for reliability of non-return valve system.

11. Pull machine screw and measure diameter of screw, barrel and non-return valve to determine wear per the machine’s tolerances.

12. Venting – Check all molds for appropriate depth and width. Identify/repair repair. Implement a system to check and clean vents. Eliminate any venting done by ‘wedging’ – tape, labels etc around the cavity that keep the mold from closing completely.

13. Start a Productivity Improvement suggestion program from the floor employees. Implement at least three suggestions. Show profit improvements.

14. Setup a 5S+1 program

15. Reduce setup times (from shut down of old part to new, acceptable parts) by 25% minimum

16. Identify 5 areas of waste. Reduce or eliminate what this costs by 50% minimum.

17. Implement an automation program: Optimize robotics, retro fit/re-tool a semi-automatic job to one that runs fully automatic (even if you load/unload the robot/sprue picker manually. If not possible, institute an operator training program where the manual operation can be completed within the closed mold time. Document a repeatable mold cycle (+ 5% of total) on 50+%of all hand load / semi automatic processes.

18. Train operators how to shut down a machine – a non-running machine wastes less money than one making scrap or burning material.

19. Train operators to identify acceptable parts instead of waiting for QA/QC to do it.

20. Set up an operator Safety Training program to reduce OSHA violations and injuries

21. Write a universal setup sheet, showing a complete Bill of Materials and process flow. Implement.

22. Regrind – find the maximum amount of regrind that will not affect the quality on a minimum of ten parts. Negotiate a specification change on the part.

23. Inspection / Qualifications – Study the customer’s requirements for part inspection and tool/machine qualifications. Compare to your current procedures. Match the two procedures together.

24. Melt Temperature – (A) train all technicians to take melt temperature. – Test so that at least three technicians get the same temperature within + 20C. (B) Check and correct at least ten machines to the correct melt temperature as specified by the material manufacturer, Calculate savings.

25. Inspect all machines for nozzle/mold sprue for line for line fit. Repair and refurbish.

Project Listings Page 1 of 1

PROJECT WORKSHEET FORMAT

DESCRIPTION

Briefly describe the problem:

HISTORY and PROPOSED ACTION

Gather data and create a Pareto Chart showing the problem’s impact on the company’s profitability (money lost etc.) along with a report on what the worst offender is and a proposal to eliminate or substantially reduce it. Describe the potential savings.

ACTION

Describe what you did to eliminate the problem and what changes are in place so that the problem will not repeat itself.

REPORT

1) Create a second Pareto Chart along with whatever procedures or changes are required to show the success of this project as well as the actual savings.

2) Report what was learned on this project that can be used elsewhere.

3) Describe the short comings of this project and what was learned from them.

SAVINGS

Show a calculation of the savings as the result of the successful completion of the project.

* * * * *

These forms are in Microsoft Word. They will work on any word processor format. Fill out each individual form and save it as an individual file. Get signatures from the appropriate people. Additional pages of supporting documentation can be attached for each project. Email the proposal for signature approval, Email completed project for accreditation.

PROJECTS

PROJECT WORKSHEET

Page ____ of _____

PROJECT NAME: ___________________________________________

PROJECT ID (tech’s initials + number – EXAMPLE “JJ4”) _________

ESTIMATED HOURS ________ Date Begun _______________

Student Name: ________________________________________

INSTRUCTIONS: Type in the information required. Use as many pages including charts, graphs, photos, sketches and diagrams as necessary.

DESCRIPTION:

HISTORY and PROPOSED ACTION (Pareto Chart Attached):

ACTION:

REPORT: (Before and after Pareto Charts attached)

ESTIMATED SAVINGS: Calculations based on a machine rate of $______/hour and Material costs of $______/pound/kilo (circle one)

PROJECTS

COMPLETION CHECK LIST

Student ID ______________

Contract signed Date _________ Initials _____ ______

Supervisor WJT Mentor

Scientific Molding test complete Date _________ Initials _____ ______

Supervisor WJT Mentor

Troubleshooting test complete Date _________ Initials _____ ______

Supervisor WJT Mentor

Project ID____ Hours _____ Date _________ Initials _____ ______

Supervisor WJT Mentor

Project ID____ Hours _____ Date _________ Initials _____ ______

Supervisor WJT Mentor

Project ID____ Hours _____ Date _________ Initials _____ ______

Supervisor WJT Mentor

Project ID____ Hours _____ Date _________ Initials _____ ______

Supervisor WJT Mentor

Project ID____ Hours _____ Date _________ Initials _____ ______

Supervisor WJT Mentor

Project ID____ Hours _____ Date _________ Initials _____ ______

Supervisor WJT Mentor

Project ID____ Hours _____ Date _________ Initials _____ ______

Supervisor WJT Mentor

Project ID____ Hours _____ Date _________ Initials _____ ______

Supervisor WJT Mentor

Project ID____ Hours _____ Date _________ Initials _____ ______

Supervisor WJT Mentor

Project ID____ Hours _____ Date _________ Initials _____ ______

Supervisor WJT Mentor

TOTAL HOURS ________ Projects must be 100 Minimum

Beginning Program Date____________

Completion Program Date ________________

PROJECTS

SCIENTIFIC MOLDING EXAM

INSTRUCTIONS

Use this page as a format. Put your answers under each topic. Use as many pages as necessary. Supplement this exam with charts and experiments (where applicable) the complete molding process.

The description should be complete enough so that someone familiar could use this document to hang the mold, start up the machine, run parts and pull the mold.

* * * * *

Student ID ______________ Date ___________

1. Describe the complete step by step procedure for installing a mold both hot runner and cold runner mold.

2. Describe the procedure for machine startup – A complete procedure of changing materials, removing the previous mold, and what to do with it once removed; how to start the machine, how to know the material is ready (dry) for processing, the method used for determining melt temperature, and a method proving both consistent waterline hookups AND that the flow to each circuit is optimal. What documents are necessary before starting up a job?

3. Write out the complete description of how to optimize each portion of the cycle.

a. clamp pressure

b. fill speed, pressure

c. determine the fill only shot

d. packing time and pressure

e. cooling time

f. ejection speed plus all distance settings

g. set up and operation of all auxiliary equipment.

4. Describe how to duplicate the optimized cycle into another machine with a different sized injection unit. – Wrong answer: “Start as though it was a new mold.”

5. Describe the procedure for purging and changing materials – example from Black 30% GF Nylon to water clear polystyrene. – Wrong answer: “Fill with new material, run until clean”

6. Describe the complete procedure for pulling a mold and sending it to storage or preventative maintenance.

7. Define an ‘Acceptable Part’ – wrong answer – “whatever the customer wants”

8. Utilize Cp or CpK on one part to show a stable process.

Scientific Molding Exam

TROUBLESHOOTING EXAM

Pick twelve of the following defects most common to your operation. For each defect write the root cause (the one cause that will explain all the individual adjustments and/or solutions. Give an explanation on how any of the major areas of processing can correct this defect.

Example – Defect: Wrong color match Root Cause: Part did not match standard color chip.

Listing of defects

1. Black Spots / Brown Specs

2. Black streaks

3. Bubbles – trapped gas

4. Burn marks

Degraded Material

5. Dieseling

6. Drooling

7. Ejector pin marks

8. Flash

9. Short Shots

10. Flowlines, weld lines

11. Inadequate colored dispersion

12. Wrong color match

13. Wrong size (different dimensions)

14. Sticking in Cavity

15. Non-uniform finish

16. Orange peel

17. Heat splay

18. Moisture splay

19. Vacuum pull / distortion

20. Screw Slippage

21. Cushion variation

22. Shot to shot inconsistency

23. Silver streaking

24. Sinks

25. Voids

26. Gate blush

27. Sticking sprue

28. Warp

29. Part cracking in mold

30. Worm tracking /jetting

31. Bad packaging

Major area of processing

a) Heat (list all types)

b) Pressure (list all types)

c) Time (list all types)

d) Speed (list all types)

e) Position (list all positions, mold and machine)

f) Equipment (state of repair/ maintenance, proper settings/ use)

g) Procedures (written, training, implementation and enforcement)

Troubleshooting Exam

TROUBLESHOOTING EXAM

Worksheet

Student name / Date

Defect:

Root cause:

Describe in a few sentences how this defect is affected by the following. Use as many pages as necessary

a) Heat (list all types)

b) Pressure (list all types)

c) Time (list all types)

d) Speed (list all types)

e) Position (list all positions, mold and machine)

f) Equipment (state of repair/ maintenance, proper settings/ use)

h) Procedures (written, training, implementation and enforcement)

Troubleshooting exam worksheet Page ___ of ___

PROJECTS

Training Resources

The following is a partial listing of training programs in the USA. There are many others nationally and internationally. Their cost is not is included in the tuition. All training is good but some programs are better than others. Contact the trainer and get a complete outline of the program, total costs, and anticipated outcome before committing to it.

Sitting through a seminar and only taking notes has limited results because your notes are rarely complete and you usually forget most of what was said within a day. Reviewing copies of the presentation slides are excellent memory joggers but they lack the words and explanations that accompanied them.

The most effective way to learn is with both a lecture type seminar (so you can ask questions) where you also receive a text book you can refer back to after the class.

Training is an investment. If can’t get a proper return on your investment, it is a waste of money.

Name / Website

1. Most OEM machine manufacturers

2. Paulson training / Injection

3. Roustis / cbt/im

4. RJG / \

5. Plastics 101 /

6. Scientific Molding by John Bozzelli /

7. Injectpro /

8. FIMMTECH – also has free calculations and information

Training Resources Page 1 of 1

DEFINATIONS

Pareto Chart – A bar chart organized with the highest frequency item on the left hand side to the lowest frequency item usually either frequency of occurrence or financial cost on the vertical axis and the individual items on the horizontal.

Pareto Study – Using Pareto Charts as the main graphic; two charts are generated: One showing the situation either historically or currently (such as the different types of scrap and their associated cost) and then after implementing the proposed changes gathering the same data and presenting it after the change is implemented. Two anticipated results should be seen in a successful Pareto Study: (1) The overall cost or frequency of what is measured should show improvement. (2) The individual items in the original chart should have changed positions showing the worst offender has had the greatest improvement and while the ‘spill over’ effect from the change will also affect the other items to varying degrees.

................
................

In order to avoid copyright disputes, this page is only a partial summary.

Google Online Preview   Download